Respirator nebulizer

ABSTRACT

An improved respirator nebulizer for introducing a water and/or medication aerosol into a flow from a respirator to a patient&#39;s respiratory system. The present invention includes a manifold body, wherethrough is passed a demand respirator low pressure main flow to a patient, and includes ducting for passing a high pressure nebulizer flow from the repirator to break up liquid from and within a cup reservoir that is scoured from that reservoir into an aerosol and encapsulated into the main flow. The manifold body, its component elements and the cup reservoir are all preferably formed by conventional molding methods and equipment, with the manifold body and component assemblies intended to be disposable after short usage or, alternatively, can be constructed to be sterilized for additional usage, with cup reservoir intended to hold a pre-measured and mixed liquid and could be disposable after a single use. The cup reservoir is arranged to be separately installed and sealed to an appropriate seat formed on the manifold body, with either the cup reservoir lip or seat incorporating grooving therein that, when the cup reservoir is attached to the manifold body, serves as liquid transport lines and nozzles wherethrough liquid from the cup reservoir is passed and sprayed. The nozzle flows impinge on or strike one another, breaking the sprays into fine particulate aerosol that is scoured from the cup reservoir by that high pressure flow and moved into the main flow. 
     The manifold preferably incorporates a two position mode valve that, in one position, passes the high pressure flow to both the nebulizer portion and to an exhalation valve, and in the other mode valve position channels the high pressure flow to perform nebulization functions only, which mode valve positioning is dependent upon the type of respirator employed with the present invention, the present invention being suitable for use with the most common Bird® and Bennett® respirators.

BRIEF DESCRIPTION OF THE INVENTION

1. Field of the Invention

The present invention relates to respirator nebulizers for use with aconventional respirator, in clinical or home inhalation therapytreatment, for humidifying and medicating a respirator low pressure mainflow.

2. Prior Art

Respirator nebulizers for creating a fine particle liquid aerosol, ofwater and/or medication, for mixing with a main flow from a conventionalrespirator for inhalation by a patient into his respiratory system are,of course, well known. Examples of such earlier devices are shown in apatent by Seeler, U.S. Pat. No. 3,083,707, with manifold type nebulizersystems shown in patents by Enfield and Huston, U.S. Pat. Nos. 3,874,379and 3,903,884. In recent times devices for performing such oxygenhumidifying have been manufactured for disposal after patient use. Ithas been found by hospitals that to provide a patient with appliancesthat are exclusively his during his stay in such a facility and todispose of them after he leaves has cut down or limited the need forsterilization facilities and more importantly reduced or limitedcross-infection between patients when sterilization was not achieved. Ithas been found in practice that it is less expensive to purchase anddispose of such appliances after each patient use than to providesterilization thereof. Examples of disposable respirator nebulizers areshown in a patent by Havstad, U.S. Pat. No. 3,826,255, and in an earlierinvention of the present inventor, U.S. Pat. No. 3,664,337. Examples ofthe nebulizing devices that were not necessarily disposable are alsoshown in patents by Bird, et al., Takaoka, and Brown, U.S. Pat. Nos.3,172,406; 3,580,249 and 3,724,454.

While the earlier cited patent by the present inventor is a significantbreakthrough in patient care, that device and the device of the HavstadU.S. Pat. No. 3,826,255, suffer from similar problems in that their use,over a period of time, may result in a patient being reinfected by hisown germs, as those devices do not lend themselves to adequate cleaning.The present invention, unlike the above cited devices and any devicewithin the knowledge of the inventor, provides smooth internal surfaceswithin a manifold body portion thereof and utilizes a separate cupreservoir attachable therewith. The cup reservoir can contain apre-measured and mixed solution and is preferably disposed of after asingle treatment.

The cup reservoir, additional to providing a disposable containeraccommodating a pre-mixed solution, is unique in that by appropriategrooves formed therein, and without additional parts or elements, itperforms nebulizing functions. Specifically, the cup reservoir lip areaand/or seat portion of the manifold body to which the cup attachesincorporate grooves therewith that, when the cup reservoir is in sealingengagement with the seat, act as fluid transfer lines and nozzlesthrough which the cup reservoir's contents, when pressurized, arepassed. The formed nozzles oppose each other such that dischargestherefrom strike one another, breaking the liquid streams into a smallparticle aerosol that is passed into and mixed with a main stream lowpressure flow from a respirator to a patient. While other prior artdevices such as those shown in patents by Babington and Glenn, U.S. Pat.Nos. 3,864,326 and 4,007,238 have shown fluid streams passed throughnozzles striking one another to produce an aerosol, none have involvedgrooves like that of the present invention that also provides, unlikeknown prior devices, a simplified assembly utilizing minimum parts,simplifying its manufacture and assembly.

Additionally, while the device of the Havstad Patent, U.S. Pat. No.3,826,255, shows an arrangement for operating a nebulizer with the twomost common respirator configurations, i.e., configurations known as theBird® and Bennett® modes, neither it or any device within the knowledgeof the inventor employs a simple valve configuration and internalducting like that of the present invention to provide for modeswitching.

The present invention is therefore believed to be unique from any knownprior art devices and a significant improvement over respiratornebulizers currently known and in use.

SUMMARY OF THE INVENTION

It is the principal object of the present invention in a respiratornebulizer to provide a device for injecting an aerosol of fine liquidparticles into a main respirator flow, the nebulizer having a minimum ofcomponent parts that can be formed by conventional injection and moldingprocesses for press-fitting together.

Another object of the present invention is to provide a respiratornebulizer that is inexpensive to produce for use by a single patientduring his stay at a hospital.

Another object of the present invention is to provide a respiratornebulizer that incorporates a nebulizer portion consisting of lines andnozzles formed by appropriately grooving the lip or seat area of adetachable cup reservoir portion and connected to a high pressuresource.

Another object of the present invention is to provide a respiratornebulizer that can be used with both configurations of major respiratordevices, specifically, respirators operating in what is commonly knownas Bird® and Bennett® modes, providing thereby a universal respiratornebulizer.

Still another object is to provide a respirator nebulizer that can beswitched for use in either the Bennett® or Bird® modes by appropriatemovement of a simple two position mode valve.

Still another object is to provide a respirator nebulizer that includesa manifold body formed to provide a convenient hand grip that will notinterfere with the nebulizer operation and minimizes a torquetransferred to the patient's hand by the weight of a tubing assemblyconnected thereto to reduce patient fatigue and discomfort.

Still another object is to provide a device that will nebulize liquidinto an aerosol of different size particles that may or may not containmedication and will encapsulate that aerosol into a main respiratorflow, which device is inexpensive to fabricate, preferably by moldingmethods, and has few component parts with smooth internal surfaces tofacilitate cleaning thereof.

The principal features of the present invention in a respiratornebulizer include a manifold body including internal respirator andpatient main flow conduits formed at a ninety degree angle with oneanother. This arrangement provides a convenient patient hand-grip at therespirator flow conduit with a mouth-piece secured to the open end of apatient flow conduit. The manifold body, in addition to passing a mainlow pressure respirator flow, is arranged to receive a respirator highpressure nebulizer flow through a two-position mode valve. The modevalve in one position divides the high pressure flow to nebulize aliquid into an aerosol in a cup reservoir portion and move and mix thataerosol into the main flow, and uses the other portion of that highpressure to operate an exhalation valve arranged in the manifold body.When the mode valve is switched to its other position, the high pressureflow will be used for liquid nebulizing only. The manifold body includesstraight passageways therein to facilitate cleaning so as to inhibitbacteria growth.

The above mentioned cup reservoir is intended for a single use only andis arranged for securing in sealing engagement to an appropriate seatformed on the manifold body. The cup reservoir is preferably prefilledwith liquid and medication, as desired, for attachment to the manifoldby an appropriate latch mechanism, the cup lip sealing to the seat. Thecup lip face that engages the seat or the seat itself is formed withgrooves therein that serve, when the cup is sealed to the seat, asliquid transfer lines and opposing nozzles. So arranged, when a highpressure flow is directed appropriately into the cup reservoir, theliquid therein will be forced through the nozzles, spraying therefromagainst one another, breaking that liquid into fine particle aerosol.The aerosol is scoured from the cup reservoir and passed by the highpressure flow into the center of the respirator main flow, encapsulatingit therein to humidfy and medicate that flow to a patient's respiratorysystem during inhalation.

As stated above, the respirator nebulizer of the present inventionprovides an exhalation valve with the manifold body that can,alternatively and dependent upon mode valve positioning, receive apressure flow through a passage in the manifold body, or can bepressurized by an external line. Thereby, by appropriately positioningthe mode valve, the present invention can be operated with a two-feedline respirator, one such arrangement commonly known as a Bird® mode, ora three-feed line respirator, one such arrangement commonly known as aBennett® mode. These configurations, Bird® and Bennett®, are the mostcommon respirator configurations and both are operated by patientdemand.

The respirator main flow is, of course, a low pressure flow that iscontrolled by patient demand. Patient exhalation passes through anexhalation valve in the manifold body when the respirator flow is cutoff by a patient beginning his exhalation cycle. That patient exhalationis passed out of the manifold body through a discharge port.

Further objects and features of the present invention will become moreapparent from the following detailed description, taken together withthe accompanying drawings.

THE DRAWINGS

FIG. 1 is a profile perspective view of the respirator nebulizer of thepresent invention showing a cup reservoir therewith that is releasablysecured to a seat formed in a manifold body, and includes a mouthpiece;

FIG. 2, an end plan view of the cup reservoir of the respiratornebulizer of FIG. 1, showing a lip face thereof having grooves formedtherein that, when the cup face is sealed against the seat in themanifold body, form transfer lines and opposing nozzles, such thatliquid within the cup is transferred and sprayed therethrough, breakingthat liquid into the small particles shown;

FIG. 2(a), a profile perspective view of the cup reservoir of FIG. 2,and showing a thin cover being removed therefrom;

FIG. 2(b), a view like that of FIG. 2(a), showing one set of groovesforming transfer lines and a nozzle, the spray therefrom shown impingingor striking against the opposite cup reservoir interior wall to breakthat liquid into small particles;

FIG. 3, an expanded end view of a cup reservoir seat formed in themanifold body of FIG. 1, showing grooves formed therein that should betaken as being the same as, and functioning like, the grooves formed inthe cup reservoir lip of FIG. 2;

FIG. 4, a sectional view taken along the lines 4--4 of FIG. 1, showingthe respirator nebulizer manifold body and cup reservoir interiors;

FIG. 5(a), a sectional view taken within the lines 5--5 of FIG. 4,showing an exploded view of an exhalation valve arranged in the manifoldbody shown positioned in a Bennett® mode of operation;

FIG. 5(b), a sectional view taken within the lines 5--5 of FIG. 4,showing an exploded view of the exhalation valve of FIG. 5(a) shownpositioned in a Bird® mode of operation; and

FIGS. 6(a) through (d) show sectional views of the mode valve,exhalation valve, exhalation cap, and portions of the manifold body andcup reservoir of FIG. 4 and illustrate patient inhalation and exhalationcycles with, in FIGS. 6(a) and 6(b), the mode valve positioned in theBird® mode, and in FIGS. 6(c) and 6(d), the mode valve positioned in theBennett® mode.

DETAILED DESCRIPTION Background of the Invention

Increasingly over the past few years, short-term and long-term patientcare facilities have tended to turn away from sterilization of medicalequipment between patient usages to a utilization of disposableequipment. When a patient enters such a facility, he is currently givencertain medical items for his personal use, which items are disposed ofat his departure. Obviously, this practice has greatly cut down on theneeds for sterilization facilities and personnel and has reduced thedanger of infecting one patient with the germs of another. However,particularly in the respirator care area where a patient could be onoxygen over a long period of time, it has been found that respiratornebulizers have traditionally been difficult to clean effectively with apatient's own germs tending to reinfect him. The present inventionprovides a second generation of such disposables and has solved thisproblem of patient reinfection by providing smooth internal surfacesthat lend themselves to cleaning and a cup reservoir that is disposableafter each treatment that preferably include grooves therein thatfunction as nebulizer component assembly. Within the cup reservoir anexact pre-measured solution of water and medication is contained for useby removal of a film cover, the grooves preferably formed in the cupreservoir lip acting as transfer lines and opposing nozzles. Thesolution is sprayed through the nozzles with sufficient velocity thatthe sprays upon striking one another break the solution into a smallparticle aerosol that is transferred into a main respirator flow andtravels into a patient's respiratory system.

The present invention is a simplified device from past nebulizers whosenebulization components have generally involved numberous parts thatremained with the device until it was disposed of. The cup reservoir ofthe present invention, as it can be manufactured as a single unitseparately from the manifold body, greatly simplifies the manufacture ofthe manifold body portion and assembly thereof. The resulting respiratornebulizer is therefore less costly, more simple to assemble, and willoperate more efficiently than former devices to produce greaterconcentrations of small size fluid particles for injection into apatient's respiratory tract than former devices. Also, it is a universaldevice in that it can be used in both conventional respirator modes,i.e., the Bennett® and Bird® modes. Further, the present invention,depending upon the materials from which it is manufactured, could bearranged for sterilization and re-use, as desired, and so need not bemade to be disposable after a single patient use.

Referring now to the drawings:

The Invention

In FIG. 1 is shown a preferred embodiment of an improved respiratornebulizer 10 of the present invention, hereinafter referred to asnebulizer. FIG. 4 shows a cross-section of nebulizer 10 of FIG. 1illustrating the preferred internal configuration thereof. Showntherein, the nebulizer 10 preferably consists of four assemblies orcomponents that are joined together as will be described later herein.Those components consist of a manifold body 11, a cup reservoir 12, anexhalation cap 13 containing an exhaust valve 24, and a two positionpressure mode valve 14 hereinafter referred to as mode valve. Themanifold body 11 is preferably formed as a single unit from a plasticmaterial such as a polypropylene, or a like synthetic resin, byinjection molding methods. That manifold body 11 preferably consists ofa main respirator flow barrel 15, hereinafter referred to as mainbarrel, and a patient flow barrel 16, hereinafter referred to as patientbarrel. The end of the patient barrel 16 connects to a mouthpiece 17 forinsertion into a patient's mouth, not shown. The main barrel isconnected to a main flow line, not shown, from a conventionalrespirator, not show, carrying a low pressure flow, preferably oxygen.The respirator, as will be explained in detail later herein, preferablyoperates on either one or two modes. The first mode is commonly known asa Bird® mode which involves two flows, a low pressure main flow and ahigh pressure nebulizer flow. The second mode of operation is commonlyknown as a Bennett® mode which involves three flows, the low pressuremain flow, the high pressure nebulizer flow, and a third exhalationoperation flow.

In FIG. 4 the respirator barrel 15 is shown as containing a respiratorflow channel 18 that connects to and makes a right or normal angle to apatient flow channel 19 formed within patient barrel 16. So arranged, apatient can conveniently hold on to the respirator barrel 15 andconnected respirator main flow line, holding the device as a pistol todirect mouthpiece 17 into his mouth, not shown. In FIG. 4 a nebulizerflow channel 20 is arranged in the manifold body 11, centered withinpatient flow channel 19, communicating therebetween and to the interiorof cup reservoir 12, for passing, as will be described later herein, andencapsulating an aerosol from cup reservoir 12 into the respirator mainflow traveling to a patient.

Arranged within manifold body 11, in communication with the patient flowchannel 19, is an exhalation passage 21 that receives patient exhalationpassed through mouthpiece 17, that exhalation traveling to atmosphere,as will be described later in detail herein. Formed also in the manifoldbody 11 is a seat 22 wherein the mode valve 14 is pivotally secured.Communicating with that seat 22 is an exhalation valve passage 23 fortransferring an air flow therethrough into a chamber 13a above anexhalation valve 24, as will be described in detail later herein, toclose off exhalation passage 21 during patient inhalation.

Shown in FIGS. 1 and 4, formed on manifold body 11 and extending from anend 11a thereof opposite to mouthpiece 17, is a cup reservoir hood 25,hereinafter referred to as hood. The hood 25 preferably extendsoutwardly from and partially encircles a flat end 11a of manifold body11. The flat end 11a preferably has a cup reservoir seat arrangedthereon. Shown in FIG. 1, the hood 25 extends at a normal angleoutwardly from manifold body end 11a, terminating in parallel latchmounting brackets 26 that extend from either side thereof, with a web 27extending thereacross. Pivot grooves 28 are formed in each latchmounting bracket to accommodate ends of a pivot 31 of a latch 29,installed therein. Latch pivot 31 is forced along groove side 28a intoopening 28b, journaling the latch 29 thereto. Latch 29 also incorporatesstiffeners 30 therewith for adding strength thereto. Shown best in FIG.4, the latch 29 includes a cam 32 formed therewith alongside pivot 31.Cam 32 incorporates a flat face 33 therewith such that, as shown best inFIG. 4, when the latch 29 is rotated appropriately the edge of that flatface 33 pivots across the cup reservoir bottom 12a the cam flat face 33coming to rest against the cup reservoir bottom 12a locking a flat lip35 of the cup reservoir 12 against a cup reservoir seat 36 that isformed in the manifold body end 11a. So arranged, with a gasket 37arranged between the cup reservoir lip 35 and cup reservoir seat 37 asshown best in FIG. 4, a seal is maintained such that a liquid containedin the cup reservoir 12 will not leak when the nebulizer is turned tothe attitude shown in FIGS. 1 and 4. To provide for exact alignment andpositioning of the cup reservoir lip to the cup reservoir seat, a dog39, shown best in FIGS. 1 and 4, is arranged to receive a cup reservoirlip edge 35a. So arranged, the cup reservoir is pivoted around edge 35athereof within an open area 39a of dog 39 to the attitude shown in FIGS.1 and 4, moving the cup reservoir lip 35 against the cup reservoir seat36 and thereafter latch 29 is rotated to the attitude shown in FIGS. 1and 4 to lock the reservoir cup 12 to the manifold body 11. Stiffeners40 are preferably arranged along side 12b of cup reservoir 12 tostrengthen that cup and engage the undersurface of hood 25 topositioning the cup reservoir 12 within the hood 25, providing a thirdpoint of contact maintaining the cup reservoir lip 35 exactly positionedagainst the cup reservoir seat 36.

It should be obvious that the arrangement of hood 25 shown in FIGS. 1and 4 could be inverted with respect to cup reservoir seat 36, the openarea of hood 25 facing upwardly, or appropriate parallel tracks could beincluded with the cup reservoir seat 36, not shown, to accomodateopposite cup reservoir lip edges slid therein, either of whicharrangements would still fall within the scope of this disclosure. Soarranged the configurations of the latch 29 and dog 39 would have to bealtered appropriately.

Additional to the above-described elements, the manifold body 11 alsoincludes the exhalation valve 24 and parts associated therewith that arearranged within the exhalation cap 13. The exhalation cap 13, as shownbest in the sectional view of FIG. 4, preferably includes an exhaustport 41, that is in communication with chamber 13a within exhalation cap13 above the exhalation valve 24. The exhalation cap 13, as shown bestin FIGS. 1 and 4, is formed with a post 13c and ball 13b arranged on topthereof and includes a skirt 42 that extends downwardly therefrom overthe exhalation valve seat of the manifold body 11. The skirt 42 issealed to an edge 43a of a plate 43 by forcing it thereover until agroove 42a, formed around the skirt interior passes into that plate edge43a. Plate 43, as shown in FIG. 4, extends at a normal angle to theexhalation passage 21.

The exhalation cap 13, like manifold body 11 and cup reservoir 12, isalso preferably formed by injection molding methods and techniques, froma suitable synthetic resin such as polypropylene, and is press fit tomanifold body 11 as described hereinabove. When exhalation cap 13 is soinstalled, an end of an internal pier 44, will maintain a rim 45a of aninverted top hat diaphragm 45, hereinafter referred to as diaphragm, ofexhalation valve 24. So arranged, as shown best in FIG. 4 and FIGS. 6(a)through 6(d) the diaphragm 45 is maintained at its rim 45a to movevertically, to lift off a seat end 21a of exhalation passage 21. Thediaphragm 45 is thereby moved upwardly, opening the exhalation passage21 to pass an exhalation flow into exhalation port 41. Functioning ofthe exahalation valve 24 during inhalation and exhalation cycles, willbe described later herein with respect to FIGS. 6(a) through 6(d).

As stated earlier herein, exhalation valve passage 23 extends from modevalve 14, emptying above diaphragm 45 within chamber 13a, in Bird® modepositioning. The mode valve 14 is closed when in the Bennett® mode withdiaphragm pressurization then supplied by a third pressure line from therespirator, not shown, that connects to a port 46 in the exhalation cap13 and empties also into the chamber 13a. Port 46 when not connected tothe respirator in the Bennett® mode of operation, as when the nebulizer10 is operating in the Bird® mode, acts as an exhaust flow control portfor exhausting pressure from chamber 13a. A constriction 46aispreferably provided in port 46 for limiting air flow therethrough. Soarranged, when the nebulizer 10 is operating in the Bird® mode, with theexhalation valve 24 pressurized through line 23, while a pressure bleedwill be continuous past constriction 46a, there will remain sufficientpressure in chamber 13a due to the size of that constriction, tomaintain exhalation valve 24 in a sealed attitude during patientinhalation.

Shown in FIG. 1 and FIGS. 5(a) and 5(b), mode valve 14 preferablyincludes a pivot arm 50 arranged therewith that can be moved between asmall letter b and a capital letter B. Small "b" is intended torepresent the Bird® mode of respirator operation, with the capital "B"to represent the Bennett® mode of respirator operation. It should beunderstood the mode valve is appropriately fitted into seat 22 to becapable of pivoting therein but is sealed to prohibit a pressure flowtherearound into passage 23 when turned to the attitude shown in FIG.5(a). Shown in cross-sectional view of FIG. 4, mode valve 14 consists ofa rod, dowel, or a like configuration that should be understood to bepivotally mounted within manifold body 11, and is center bored at 14ahaving a portion 52 thereof removed strategic to the opening to thepassage 23. Mode valve 14 should be understood to be continuously opento a nebulizer passage 60, and can, with appropriate rotation, move apart of a solid area 51 over the exhalation valve passage 23. Thenebulizer and exhalation passages, of course, are offset with oneanother. So arranged, as shown in FIG. 5(a), where the arm 50, shown inbroken lines, is rotated to point to the capital "B", that solid area 51will close off exhalation valve passage 23, prohibiting air flowtherethrough. Whereas, as shown in FIG. 5(b), with the arm 50, shown inbroken lines, moved to the attitude shown by the small letter "b", thehigh pressure flow entering through 14a will pass both throughexhalation valve passage 23 and nebulizer passage 60.

Therefore, by a simple movement of arm 50 of mode valve 14, it ispossible to switch from the Bird® mode of respirator operation to theBennett® mode. Operation of exhalation valve 24 in relation to theappropriate positioning of mode valve 14 will be explained in greaterdetail later herein with respect to FIGS. 6(a) through 6(d).

As stated hereinabove, the nebulizer 10 of the present inventionpreferably includes four components that are molded and coupled togetherinto the invention. The described mode valve 14, exhalation cap 13 withthe exhalation valve 24 therein, of course, once they are fitted to themanifold body 11 are integral to the unit. The cup reservoir 12,however, is intended to be manufactured separately and is forreplacement after each treatment. Whereas, the nebulizer 10, less cupreservoir 12, is intended to be replaceable or disposable after apatient has discontinued respirator treatment, and can even befabricated so as to be capable of being sterilized for re-use by a newpatient.

The cup reservoir 12 is intended, as described earlier herein, to bemounted in releasable sealing engagement to a cup reservoir seat 36formed in end 11a of manifold body 11 and provides a capability ofcontaining a desired pre-measured and pre-mixed solution of water andmedication therein. Shown in FIG. 2(a) the cup reservoir is preferablysealed, as with a film covering 12c after filling, which covering isremoved prior to attachment to manifold body 11. Obviously, with asolution in the cup reservoir 12 and film 12c removed, to install thecup reservoir as shown in FIGS. 1 and 4, it is necessary to tip themanifold body 11 appropriately such that mouthpiece 17 extendsvertically. Whereafter, the cup lip 35 can be installed such that theedge 35a thereof fits in the opening 39a and the latch 29 is rotated topivot cam flat face 33 into engagement with the cup reservoir end 12a.So arranged, the cup reservoir lip 35 is sealed to the cup reservoirseat 36 with gasket 37 therebetween, and the nebulizer 10 can then bepivoted or rotated to the attitude shown in FIGS. 1 and 4.

Referring now to FIGS. 2, 2(a) and 2(b), nebulizing or breaking into afine particle areosol of a solution or liquid 12b contained within thecup reservoir 12 is preferably provided by formation of liquid flowlines and nozzles as grooves in the lip 35 of cup reservoir 12. Shown inan end view of cup reservoir 12, in FIG. 2, the grooves when sealedagainst a flat face of cup reservoir seat 36 and gasket 37 form a highpressure receiving port 61 that receives a high pressure flow throughpassage 60 in manifold body 11. That high pressure flow is divided atport 61, passing through semi-circular grooves 62a and 62b that extendalong the cup reservoir lip 35 and terminate in nozzles 63a and 63b andoperate as high pressure transfer lines. Each nozzle 63a and 63b has anarrow neck or throat 64a and 64b formed therein, spreading therefrominto opposing bell-shaped discharge ends 65a and 65b. Intersecting thenozzle throats 64a and 64b are fluid transfer lines 66a and 66bwherethrough liquid 12b maintained in cup reservoir 12 is drawn by apressure differential at the throats 64a and 64. So arranged, the highpressure air flow creates a suction at the nozzle throats drawing theliquid from the cup reservoir through opening 67 into the fluid transferlines 66a and 66b, into the high pressure flow. The liquid 12b issprayed out from the opposing nozzle bell ends 65a and 65b, that directthe sprays against one another meeting at a midpoint in the cupreservoir interior. So arranged, a fluid flow picked up through port 67is sprayed out from nozzle ends 65a and 65b breaking into a fineparticle aerosol. The high pressure passed thereby into the cupreservoir 12 then scours the cup reservoir interior, picking up theaerosol and passing it into the nebulizer passage 20. The nebulizerpassage 20 passes the aerosol into the center of the respirator flow,and moving with the respirator flow passing through mouthpiece 17 to thepatient. By impacting the spray from one nozzle against the other, thecumulative impact velocity doubles over what it would be with one sprayhitting a solid object, thereby creating a large percentage of fineliquid particles, with large particles falling back into the liquid 12bwithin cup reservoir 12. Also, as the velocity of the spray is dependentupon the flow volume through the nozzles and therefore is governed bythe geometry of the transfer lines and nozzles, by an appropriateselection or formation of the transfer lines and nozzles the sprayvelocity can be regulated to produce a desired size of aerosolparticles. So arranged, by appropriate coding, as say with differentcolors, cup reservoirs 12 having certain geometry of transfer lines andnozzles to produce a desired aerosol particle size can be identified.Such color coding could involve different colors of the cup reservoir 12itself, or as shown in FIG. 2(a), by color coding of film 12c.

While the above arrangement of two opposing nozzles is preferred, FIG.2(b) shows an alternative grooving of liquid transfer and nozzlearrangement. In this arrangement, a high pressure nebulizer flow entersport 61 in cup reservoir lip 35 from passage 60 and travels into asingle semi-circular groove 62c that operates as a high pressuretransfer line. The flow then enters a single nozzle 63c passing througha narrow neck or throat 64c thereof and out a bell shaped discharge end65c. Similar to the operation described with respect to FIGS. 2 and2(a), liquid from the cup reservoir is pulled through opening 67 andthrough a single fluid transfer line 66c by a pressure differentialcreated at the narrow neck or throat by the high pressure flowtherethrough, mixing with the air flow through throat 64c. In thisembodiment, however, unlike the embodiment described in FIGS. 2 and2(a), a flow from that nozzle is directed to strike against the oppositecup reservoir 12 interior wall, as shown in FIG. 2(b). The dischargefrom nozzle 63c strikes the wall, breaking up the liquid and air flowinto a fine particle aerosol, functioning like the arrangements shownand described with respect to FIGS. 2 and 2(a). While single and twoopposing nozzles 63a, 63b and 63c and the connecting transfer lines asshown herein are preferred, it should be obvious that additional nozzlescould be included, which inclusion would still fall within the scope ofthis disclosure.

The description hereinabove, with respect to FIGS. 2, 2(a) and 2(b),shows grooves formed in the lip 35 of cup reservoir 12 with the cupreservoir seat 36 and gasket 37 as flat surfaces. Alternatively, andwithout departing from the subject matter coming within the scope ofthis disclosure, the cup reservoir seat 36 in the manifold body end 11acould be grooved appropriately. In this configuration, the lip 35 of thecup reservoir 12 would preferably be a smooth flat surface as wouldgasket 37 to close off said grooves, thereby forming the describedtransfer lines and nozzles. Nebulizing operations of the arrangement ofFIG. 3 should be taken as being exactly like that shown and describedwith respect to FIG. 2(a), and therefore the same numbering has beenapplied to those grooves as was given to the grooves of FIG. 2(a), thegrooves of FIG. 3 being a mirror image to the grooves of FIG. 2(a).

Operation

With nebulizer 10 arranged in the Bird® mode, as shown in FIGS. 1, 4 and5(b), a low pressure flow from respirator, not shown, preferably oxygen,travels through respirator flow channel 18 joining and encapsulating theaerosol produced in the cup reservoir 12 as it exits nebulizer flowchannel 20. The flown then travels through the patient flow channel 19and mouthpiece 17 into a patient's respiratory system. The respirator,not shown, produces the main low pressure flow and a high pressurenebulizer flow. The high pressure nebulizer flow travels through modevalve 14, entering through inlet 14a, passing, as shown in thearrangement of FIG. 5(b), through passage 23 above exhalation valve 24.These flows are controlled by patient demand in that, when a patientinhales, a pressure differential is created at the respirator thatoperates appropriate valving therein to initiate the described flow.During patient exhalation, when the patient breathes back against therespirator flow, a back pressure is sensed at the respirator thatdiscontinues the flows therefrom. Therefore, the patient controlsoperations of the respirator, that, in turn, provides the needed flowsand controls nebulizer 10 operation.

FIGS. 6(a) and 6(b) show the nebulizer 10 operated in Bird® mode ofrespirator operation, and include arrows that indicate air flow duringpatient inhalation and exhalation. So arranged, the mode valve 14 ispositioned to the Bird® mode passing a portion of the high pressure flowthrough passage 23. Shown in FIG. 6(a ) therein, the low pressure flow,arrow "A", travels through respirator flow channel 18 and into patientflow channel 19 wherein it is mixed with a flow, arrow "B", coming fromcup reservoir 12 that contains an aerosol of fine particles of water andis optionally medicated. Of course, the patient is, at this time,inhaling. Nebulization of the cup reservoir 12 contents is provided byhigh pressure nebulizer flow, arrow "B", that is shown dividing at modevalve 14, part passing through nebulizer passage 60, the balance passingthrough exhalation valve passage 23, into chamber 13a above diaphragm 45of exhalation valve 24. The diaphragm 45 is thereby pressed downwardlyon the seat area 21a of exhalation passage 21, closing that passage offduring patient inhalation. Port 46 is open to atmosphere and ventspressure shown by arrow "B". Flow through port 46 is controlled byconstriction 46a to retain sufficient pressure in chamber 13 a to holdexhalation valve 24 closed during patient inhalation.

Shown in FIG. 6(b), at the time when the patient begins to exhaust gasfrom his lungs, that back pressure will shut off the respirator,discontinuing the respirator flows, pressure within chamber 13a, arrow"D", exhausting through port 46. The patient exhalation travels aroundnebulizer passage 20, and into exhaust passage 21 elevating diaphragm 45off from exhaust passage seat 21a, the flow traveling out the exhaustport 41. Whereafter, the cycle is repeated.

Referring to FIGS. 6(c) and 6(d), shown therein are inhalation andexhalation cycles like that described with respect to FIGS. 6(a) and6(b) hereinabove, only showing the mode valve 14 of nebulizer 10 turnedto operate in the Bennett® respirator mode. Shown therein, a lowpressure flow, arrow "A", from the respirator, not shown, passes throughthe respirator main flow channel 18 and encapsulates the aerosol comingfrom the nebulizer flow channel 20, shown as arrow "B", the combinedflows traveling to the patient through patient flow channel 19. In thisconfiguration, the high pressure nebulizer flow passes through modevalve 14 and into passage 60 only, to nebulize the contents of cupreservoir 12, as has been hereinbefore described. This respiratorarrangement includes a third pressure line coming from the respirator,not shown, identified as arrow "C", that connects to port 46 to pass anair pressure flow into chamber 13a above the diaphragm 45 of theexhalation valve 24. Shown in FIG. 6(c), that pressure, arrow "C", holdsthe diaphragm 45 against exhalation passage seat 21a, prohibiting airflow therearound during patient inhalation. In the arrangement of FIG.6(d), inhalation has ceased and the patient is exhaling, as sensed atthe respirator that shuts off the three flows, with patient exhaustshown as arrow "D". So configured, as was described with respect to FIG.6(b), the exhaust pushes upwardly on the diaphragm 45, elevating it offthe exhalation passage seat 21a. The patient exhaust then passes outthrough the exhaust port 41. Any pressure trapped within exhalationchamber 13a, that would hold the exhalation valve closed, is bled backalong with the patient exhalation through port 46 to the respirator.

As stated earlier herein, the present invention in a nebulizer 10provides internal surfaces that are essentially smooth for simplifyingcleaning thereof and to minimize a danger of bacteria growth therein.The cross-sectional view of FIG. 4 shows that the air flow passagestherein are essentially straight with few corners simplifying cleaningthereof, and as cup reservoir 12 is intended to be disposable after eachuse it could not be a source of bacteria growth, a danger of bacteriagrowth is thereby minimized.

It should be noted, with reference to FIGS. 4 and 6(b) and 6(d), thatdaphragm 45 is preferably constructed to have the shape of an invertedhat, with upstanding side walls 45b that will flex when patientexhalation, arrow "D", is passed therethrough. Diaphragm 45, at rim 45athereof, is sealed within the top portion of exhalation cap 13,prohibiting air passage thereat.

As was stated earlier herein, the present invention is preferably formedby conventional molding methods from a synthetic resin, such aspolypropelene, or the like, and the components thereof are preferablyforce fitted together. Obviously, of course, other materials andassembly techniques could be employed without departing from the subjectmatter coming within the scope of this disclosure. Further, nebulizer 10could be formed so as to be capable of being sterilized for additionalpatient use, as desired. Mouthpiece 17, while not described in detailherein, should be considered to be a standard mouthpiece, fitted to thepatient flow channel 19, as shown, or could be slid over the outersurface of the patient flow channel 19 such that flanged ends 19athereof lock within the mouthpiece end. Further, flanged ends 18a areshown on the end of respirator flow channel 18 for facilitatingconnection to the main respirator flow line.

Although preferred embodiments and elements of the nebulizer 10 of thepresent invention are shown and described herein, it should beunderstood that the present disclosure is made by way of example onlyand that variations are possible without departing from the subjectmatter coming within the scope and spirit of the following claims, whichclaims I regard as my invention.

I claim:
 1. A respirator nebulizer comprising,a manifold body; meansarranged with said manifold body for connection to both intermittenthigh and low pressure gas flows from a respirator; first duct meansformed in said manifold body to convey said low pressure flowtherethrough to a patient's respiratory system; a cup shaped reservoir;means with said cup shaped reservoir to communicate with said first ductmeans and including lip means about its open periphery defining a flatsurface and said manifold body including seat means adapted to receivesaid lip means in sealing engagement therewith, thereby closing said cupshaped reservoir; means for releasably securing, in sealing engagement,said lip means of said cup shaped reservoir to said seat means of saidmanifold body; second duct means formed in said manifold body to passsaid high pressure flow to said seat means; means for nebulizing aliquid within said cup shaped reservoir that includes grooves formed insaid flat surface of said cup shaped reservoir lip means, which groovesform, when said lip means is sealingly engaged against said seat means,air and liquid transfer lines and nozzle means, said liquid transferline communicating the interior of said cup shaped reservoir with saidnozzle means, said air transfer line communicating with said second ductmeans, said nozzle means communicating with both said air and liquidtransfer lines such that said high pressure flow aspirates and nebulizesliquid from said reservoir and sprays said nebulized liquid into saidfirst duct means whereby said liquid is broken into a fine particleaerosol which aerosol is scoured by said low pressure flow in said firstduct; and means communicating with said first duct means for purging apatient's exhalation.
 2. A respirator nebulizer as recited in claim 1,whereinthe manifold body is formed to have a ninety degree (90°) bendtherein.
 3. A respirator nebulizer as recited in claim 1, wherein,thecup shaped reservoir has stiffeners secured along one side thereof.
 4. Arespirator nebulizer as recited in claim 1 wherein the means forreleasably securing the lip means of said cup shaped reservoir to saidseat means consists of,housing means extending from said manifold bodyto receive the cup shaped reservoir; latch means that is pivotallycoupled to said housing means for biasing the cup shaped reservoiragainst said manifold body, said latch means incorporating a cam that,when said latch means is pivoted appropriately, will engage a bottomsurface of said cup shaped reservoir urging said lip means thereof intosealing engagement with said manifold body seat means; and a gasketarranged between the cup shaped reservoir lip means and seat means.
 5. Arespirator nebulizer as recited in claim 1, wherein,the grooves in saidcup shaped reservoir lip means that form a liquid transfer lineintersect the throat of the nozzle means such that the high pressure gasflow creates a pressure differential at said throat to draw said liquidtherein.
 6. A respirator nebulizer as recited in claim 1, whereinsaidcup shaped reservoir lip means includes, a second set of gas and liquidtransfer lines and nozzle means arranged opposite said first set of gasand liquid transfer lines and nozzle means such that said second nozzlemeans points at the first nozzle means whereby the sprays from eachnozzle means will impact one another, breaking the liquid into anaerosol.
 7. A respirator nebulizer as recited in claim 1 wherein thespray from said nozzle means strikes a reservoir interior wall oppositethereto.
 8. A respirator nebulizer as recited in claim 1, wherein themeans for purging a patient's exhalation consists of,an exhalation valvemeans arranged with said manifold body to close off an exhalation flowpassage that is arranged through said manifold body, when the respiratorhigh pressure gas flow is received, said exhalation valve means arrangedto open to atmosphere when said respirator high pressure flow isdiscontinued.
 9. A respirator nebulizer as recited in claim 8, whereinthe exhalation valve means consists of,a seat arranged across saidexhalation flow passage; and a diaphragm means biased over said seat andarranged to be movable vertically off from said seat.
 10. A respiratornebulizer as recited in claim 9, wherein the diaphragm means consistsof,a top hat shaped diaphragm turned unside down with a rim thereofsecured above the exhalation flow passage seat a flat top portionthereof fitting over and biased against said seat, said biasing providedby a flexible diaphragm wall that extends between the rim and flat top;and means for securing said diaphragm rim such that said flat topthereof will extend across said exhalation flow passage seat.
 11. Arespirator nebulizer as recited in claim 8 further including a means foroperating said exhalation valve means comprising,mode valve meansarranged in said second duct means of said manifold body and adapted toreceive the respirator high pressure flow, said second duct meansfurther communicating with said exhalation valve means, said mode valvemeans being moveable to a first position, that will pass part of saidflow to close off said exhalation valve means and part of said flow tosaid nozzle means; and into a second position to pass said flow only tosaid nozzle means; and a vent port connecting to said exhalation valvemeans to vent pressure therefrom when said high pressure flow is cut offfor allowing said exhalation valve means to open to pass patientexhalation therethrough.
 12. A respirator nebulizer as recited in claim11, further including a means for operating said exhalation valve meansthat consists of,inlet means for communicating a separate respiratorhigh pressure gas flow to said exhalation valve means for passingpressure to close said exhalation valve means when said mode valve meansis in said second position and the low pressure and high pressure gasflows are passed.
 13. A respirator nebulizer comprising,a manifold body;means arranged with said manifold body for connection to bothintermittent high and low pressure gas flows from a respirator; firstduct means formed in said manifold body to convey said low pressure flowtherethrough to a patient's respiratory system; a cup shaped reservoir;means with said cup shaped reservoir to communicate with said first ductmeans and including lip means about its open periphery defining a flatsurface and said manifold body including seat means adapted to receivesaid lip means in sealing engagement therewith, thereby closing said cupshaped reservoir; means for releasably securing, in sealing engagement,said lip means of said cup shaped reservoir to said seat means of saidmanifold body; second duct means formed in said manifold body to passsaid high pressure flow to said seat means; means for nebulizing aliquid within said cup shaped reservoir that includes grooves formed insaid flat surface of said seat means, which grooves form, when said lipmeans is sealingly engaged against said seat means, air and liquidtransfer lines and nozzle means, said liquid transfer line communicatingthe interior of said cup shaped reservoir with said nozzle means, saidair transfer line communicating with said second duct means, said nozzlemeans communicating with both said air and liquid transfer lines suchthat said high pressure flow aspirates and nebulizes liquid from saidreservoir and sprays said nebulized liquid into said first duct meanswhereby said liquid is broken into a fine particle aerosol which aerosolis scoured by said low pressure flow in said first duct; and meanscommunicating with said first duct means for purging a patient'sexhalation.
 14. A respirator nebulizer as recited in claim 13,whereinthe manifold body is formed to have a ninety degree (90°) bendtherein.
 15. A respirator nebulizer as recited in claim 13, wherein,thecup shaped reservoir has stiffeners secured along one side thereof. 16.A respirator nebulizer as recited in claim 13 wherein the means forreleasably securing the lip means of said cup shaped reservoir to saidseat means consists of,housing means extending from said manifold bodyto receive the cup shaped reservoir; latch means that is pivotallycoupled to said housing means for biasing the cup shaped reservoiragainst said manifold body, said latch means incorporating a cam that,when said latch means is pivoted appropriately, will engage a bottomsurface of said cup shaped reservoir urging said lip means thereof intosealing engagement with said manifold body seat means; and a gasketarranged between the cup shaped reservoir lip means and seat means. 17.A respirator nebulizer as recited in claim 13, wherein,the grooves insaid seat means that form a fluid transfer line intersect the throat ofthe nozzle means such that the high pressure gas flow creates a pressuredifferential at said throat to draw said liquid therein.
 18. Arespirator nebulizer as recited in claim 13, whereinsaid seat meansincludes, a second set of gas and liquid transfer lines and nozzle meansarranged opposite said first set of gas and liquid transfer lines andnozzle means such that said second nozzle means points at the firstnozzle means whereby the sprays from each nozzle means will impact oneanother, breaking the liquid into an aerosol.
 19. A respirator nebulizeras recited in claim 13, wherein the spray from said nozzle means strikesa reservoir interior wall opposite thereto.
 20. A respirator nebulizeras recited in claim 13, wherein the means for purging a patient'sexhalation consists of,an exhalation valve means arranged with saidmanifold body to close off an exhalation flow passage that is arrangedthrough said manifold body, when the respirator high pressure gas flowis received, said exhalation valve means arranged to open to atmospherewhen said respirator high pressure flow is discontinued.
 21. Arespirator nebulizer as recited in claim 20, wherein the exhalationvalve means consist of,a seat arranged across said exhalation flowpassage; and a diaphragm means biased over said seat and arranged to bemovably vertically off from said seat.
 22. A respirator nebulizer asrecited in claim 21, wherein the diaphragm means consists of,a top hatshaped diaphragm, turned upside down with a rim thereof secured abovethe exhalation flow passage seat a flat top portion thereof fitting overand biased against said seat, said biasing provided by a flexiblediaphragm wall that extends between the rim and flat top; and means forsecuring said diaphragm rim such that said flat top thereof will extendacross said exhalation flow passage seat.
 23. A respirator nebulizer asrecited in claim 20 further including a means for operating saidexhalation valve means comprising,mode valve means arranged in saidsecond duct means of said manifold body and adapted to receive therespirator high pressure flow, said second duct means furthercommunicating with said exhalation valve means, said mode valve meansbeing moveable to a first position, that will pass part of said flow toclose off said exhalation valve means and part of said flow to saidnozzle means; and into a second position to pass said flow only to saidnozzle means; and a vent port connecting to said exhalation valve meansto vent pressure therefrom when said high pressure flow is cut off forallowing said exhalation valve means to open to pass patient exhalationtherethrough.
 24. A respirator nebulizer as recited in claim 23, furtherincluding a means for operating said exhalation valve means thatconsists of,inlet means for communicating a separate respirator highpressure gas flow to said exhalation valve means for passing pressure toclose said exhalation valve means when said mode valve means is in saidsecond position and the low pressure and high pressure gas flows arepassed.
 25. A respirator nebulizer comprising,a manifold body; meansarranged with said manifold body for connection to both intermittenthigh and low pressure gas flows from a respirator; first duct meansformed in said manifold body to convey said low pressure flowtherethrough to a patient's repiratory system; a cup shaped reservoir;means with said cup shaped reservoir to communicate with said first ductmeans and including lip means about its open periphery defining a flatsurface and said manifold body including seat means adapted to receivesaid lip means in sealing engagment therewith, thereby closing said cupshaped reservoir; an exhalation valve means arranged in said manifoldbody; second duct means formed in said manifold body to pass said highpressure flow to said seat means; means for nebulizing a liquid withinsaid cup shaped reservoir into a fine particle aerosol including nozzlemeans that receives said high pressure flow through air transfer linescommunicating with said second duct means and liquid from a liquidtransfer line communicating with the interior of said cup shapedreservoir such that said high pressure flow aspirates and nebulizesliquid from said reservoir and sprays said nebulized liquid into saidfirst duct means whereby said liquid is broken into a fine particleaerosol, which aerosol is scoured by said low pressure flow in saidfirst duct; mode valve means arranged in said second duct means of saidmanifold body and adapted to receive the respirator high pressure flow,said second duct means further communicating with said exhalation valvemeans, said mode valve means being moveable to a first position, thatwill pass part of said flow to close off said exhalation valve means andpart of said flow to said nozzle means; and into a second position topass flow only to said nozzle means; means for releasably securing, insealing engagement, said lip means to said seat means; passage meanswithin said manifold body to receive said patient's exhalation and passit to said exhalation valve means; and a vent port located downstreamfrom said exhalation valve means to vent pressure therefrom when saidhigh pressure flow is cut off allowing said exhalation valve means toopen to pass patient exhalation therethrough.
 26. A respirator nebulizeras recited in claim 25, wherein,the manifold body is formed to have aninety degree (90°) bend therein.
 27. A respirator nebulizer as recitedin claim 25, wherein,the cup shaped reservoir has stiffeners securedalong one side thereof.
 28. A respirator nebulizer as recited in claim25 wherein the means for releasably securing the lip means of said cupshaped reservoir to said seat means consists of,housing means extendingfrom said manifold body to receive the cup shaped reservoir; latch meansthat is pivotally coupled to said housing means for biasing the cupshaped reservoir against said manifold body, said latch meansincorporating a cam that, when said latch means is pivotedappropriately, will engage a bottom surface of said cup shaped reservoirurging said lip means thereof into sealing engagement with said manifoldbody seat means; and a gasket arranged between the cup shaped reservoirlip means and seat means.
 29. A respirator nebulizer as recited in claim25, wherein the exhalation valve means consists of,a seat arrangedaround said exhalation flow passage; and a diaphragm means biased oversaid seat, and arranged to be movable vertically off from said seat. 30.A respirator nebulizer as recited in claim 29, wherein the diaphragmmeans consists of,a top hat shaped diaphragm, turned upside down, with arim thereof secured above the exhalation flow passage seat, a flat topprotion thereto fitting over and biased against said seat, said biasingprovided by a flexible diaphragm wall that extends between the rim andflat top; and means for securing said diaphragm rim such that said flattop thereof will extend across said exhalation flow passage seat.